Composite gaming chip and method of manufacturing

ABSTRACT

A gaming chip is formed of a composite material comprising a polymer and from about 5 to 50% by weight of organic filler. The gaming chip may be formed by injection molding. In a specific embodiment, the gaming chip comprises at least one first portion in which the composite material comprises a first colored pigment and at least one second portion in which the composite material comprises a second colored pigment different from the first colored pigment to thereby provide a multicolor gaming chip.

FIELD OF THE INVENTION

The present invention is directed to a gaming chip, and, more particularly, to a gaming chip formed of a composite material and having an improved combination of look, feel and durability. The invention is also directed to methods of manufacturing a gaming chip.

BACKGROUND OF THE INVENTION

Gaming chips or tokens are well known for use in card games and the like. Many times, such gaming chips are formed entirely of plastic, for example by injection molding, and are therefore easily mass produced. However, such chips are relatively light weight and often are not preferred for use where a heavy, more substantive feeling chip is desired. Chips formed of clay typically have a heavy, substantive feel. However, clay chips are relatively fragile and often crack or break when they are dropped, or even during normal handling, and therefore require careful handling to avoid chip destruction. Such careful handling is often inconvenient during card playing and associated activities.

Other gaming chips have been formed entirely of metal and these chips are typically of a higher weight and provide a more substantive feel as compared with plastic chips. However, metal chips are significantly more expensive to produce as compared with injection molded plastic chips. The metal chips can also be advantageous for use in applications where detection of the presence of the metal chip by, for example, conductivity measurements, are desired.

Composite gaming chips formed of both metal and plastic materials are also known. For example, the Jones U.S. Pat. Nos. 3,968,582 and 4,827,640 disclose gaming tokens which may be formed of both metal and plastic components in combination. The Boiron U.S. Pat. No. 6,021,949, the Shumi et al U.S. Pat. Nos. 6,372,320 and 6,488,210 and the Zurawski et al U.S. Pat. No. 6,514,374 disclose additional gaming tokens or chips which may be formed of a plurality of materials and components. However, gaming chips or tokens which are formed of a plurality of components are often of a construction which does not facilitate mass production. Accordingly, further improvements in gaming chips are desired.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide novel gaming chips which have a good substantive feel. It is an additional object of the invention to provide gaming chips and methods for manufacturing gaming chips which are amenable to mass production.

In one embodiment, the invention is directed to a gaming chip which is formed of a composite material comprising a polymer and from about 5 to about 50 percent by weight of inorganic filler.

In a further embodiment, the invention is directed to a method of manufacturing a gaming chip. The method comprises injection molding a composite material in the form of a gaming chip, the composite material comprising a polymer and from about 5 to about 50 percent by weight of inorganic filler.

The gaming chips according to the present invention are advantageous in comprising plastic material while exhibiting a good substantive look and feel, and exhibiting improved resistance to cracking and breakage as compared, for example, with clay chips. Additionally, the gaming chips may be manufactured according to a method which facilitates mass production. These and additional objects and advantages will be more fully apparent in view of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be more fully understood in view of the drawing in which:

FIG. 1 is a top view of a first embodiment of a gaming chip according to the invention;

FIG. 2 is an enlarged cross sectional view of the gaming chip of FIG. 1 taken along line 2-2;

FIG. 2A is an enlarged cross-sectional view of the gaming chip of FIG. 1 taken along line 2A-2A;

FIG. 3 is a top view of a first portion included in the embodiment of the gaming chip shown in FIG. 1;

FIG. 4 is a cross sectional view of the first portion of FIG. 3 taken along line 4-4; and

FIG. 5 is a cross sectional view of a mold in which the first portion shown in FIG. 3 is formed during manufacture of a gaming chip according to the present invention.

DETAILED DESCRIPTION

The gaming chips according to the present invention are formed from a composite material comprising a polymer and an inorganic filler. The composite material provides the gaming chips with a good, substantive feel, and improved durability, whereby the chips resist cracking and breaking during normal handling and even when dropped.

More particularly, the composite material comprises a polymer and from about 5 to about 50 percent by weight of inorganic filler, based on the weight of the gaming chip. The polymer may comprise the substantial balance of the composite material, and therefore be present in an amount of from about 50 to about 95 percent by weight. Alternatively, the composite material may contain additional components, for example, pigments, stabilizers, processing aids, additional filler materials, and the like. It is preferred however that at least about 30 percent by weight, more preferably at least about 50 percent by weight, of the gaming chip comprises polymer. In a more specific embodiment, the composite material comprises a polymer and from about 5 to about 25 percent by weight of inorganic filler. In an additional embodiment, the composite material comprises from about 75 to about 95 percent by weight polymer, and optionally coloring pigment, and from about 5 to about 25 percent by weight of inorganic filler.

Any polymer which provides the desired rigidity to the gaming chip may be included in the composite material. In one embodiment, however, it is preferred to include a polymer which is easily injection molded, in order to facilitate mass production. In one embodiment, the polymer comprises polyolefin, examples of which include, but are not limited to, polyethylene homopolymers and copolymers, and polypropylene homopolymers and copolymers, polyacrylate, polymethacrylate, polycarbonate, polyurethane, or the like, and any combination thereof. In a specific embodiment, the polymer comprises polyolefin, and, more specifically, polypropylene.

Any inorganic filler which increases the weight of the polymer may be used, but it is preferred that the inorganic filler also contribute to provide a clay-like feel to the surface of the gaming chip. In one embodiment, the filler comprises metal oxide, metal hydroxide, metal carbonate, or a mixture of two or more thereof. Included within these groups are clays, typically comprising hydrated aluminum silicates and alkali and alkaline earth oxides, hydroxides and carbonates, and the like. In a more specific embodiment, the filler comprises clay, silica, calcium carbonate, or a mixture thereof.

In a yet further embodiment, the composite material comprises a polyolefin such as polypropylene and an inorganic filler such as calcium carbonate. For example, the composite material in a more specific embodiment comprises from about 50 to about 95 percent by weight polypropylene and from about 5 to about 25 percent by weight calcium carbonate filler, and optionally contains one or more coloring pigments in small amounts sufficient to provide desired coloring.

With reference to the drawings, FIGS. 1 and 2 set forth top and cross sectional views of a first embodiment of a gaming chip 10 according to the invention. The gaming chip 10 includes a perimeter 12 and a body 14 within the perimeter 12. The body 14 as shown in FIGS. 1 and 2 includes opposed faces 14 a and 14 b. In one embodiment, the faces 14 a and 14 b are substantially planar in their configuration, whereby any variations in the thickness of the chip 10 across the body 14 are less than several mils. In one specific embodiment, there is a slight variation in the thickness of the body at selected areas, as described in further detail herein. The gaming chip 10 is of a substantially circular shape as shown in FIG. 1, although other shapes of gaming chips are equally within the scope of the invention.

The gaming chip may be formed of a composite material of a single color or alternatively may be formed of two or more colors by providing separate portions of the composite material with different colorings. The gaming chip 10 of FIGS. 1 and 2 is formed of two composite material portions. More particularly, the gaming chip 10 comprises a first portion 20 in which the composite material comprises a first colored pigment, and a second portion 22 in which the composite material comprises a second colored pigment different from the first colored pigment of the first portion 20, thereby combining to form a multi-colored gaming chip. Within the present description, the term “colored pigment” encompasses any additive which colors the composite material and includes, but is not limited to, inorganic coloring pigments, organic coloring pigments, dyes and the like. As shown in FIGS. 1 and 2, the second portion 22 may be formed as a single part, with all areas interconnected together. Similarly, as shown in FIGS. 3 and 4, the first portion 20 may be formed as a single part, with all areas interconnected together. However, the gaming chip may alternatively comprise any number of parts of the first and second portions of differing color as desired for identification, aesthetic or manufacturing purposes. Similarly, the gaming chip may include additional portions formed of additional differently colored composite material.

In a specific embodiment, the first portion is provided with at least one surface indentation in which the second portion is located to form the completed chip. FIGS. 3 and 4 show the first portion 20 of the gaming chip 10 in more detail. The first portion 20 extends substantially around and forms the perimeter 12 of the chip and extends substantially across the body 14 of the chip within the perimeter 12.

In one embodiment, each body surface 21 a and 21 b of the first portion 20 is provided with at least one indentation and the second portion 22 is located in each indentation. Further, the perimeter of the first portion may include indentations, with a second portion located in each indentation. In the embodiment shown in FIGS. 3 and 4, the first portion 20 is provided with surface indentations 30 in the form of stripes adjacent the chip periphery, with additional surface indentations 32 and 34 in the form of playing card indicia (heart, club, spade, diamond) adjacent the chip periphery on opposite faces of the first portion 20, and indentations 36 and 38 in the vicinity of the center of the opposite faces of the first portion. The various indentations 30, 32, 34, 36 and 38 are all interconnected with one another, with apertures 40 extending between the body surfaces to interconnect the indentations on one body face 21 a with those on the opposite body face 21 b. In one embodiment, indentations at the chip periphery may extend from one body face 21 a to the opposite body face 21 b to provide the periphery surface 42 of the chip with a multicolor pattern.

The second portion 22 of the gaming chip 10 is located in the indentations of the first portion 20. Thus, as shown in FIGS. 1 and 2, parts 50 of the second portion are located in the indentations 30, parts 52 of the second portion are located in the indentations 32, parts 54 of the second portion are located in the indentations 34, parts 56 of the second portion are located in the indentations 36, and parts 58 of the second portion are located in the indentations 38. Additionally, parts 60 of the second portion are located in the apertures 40 of the first portion. Thus, the second portion parts are interconnected to form a single piece.

In the embodiment of the gaming chip set forth in FIGS. 1 and 2, the surfaces of the second portion 22 are substantially coplanar with the non-indented surfaces of the first portion 20, whereby any variations in the thickness of the chip in the body 14 are less than several mils. In one embodiment, there is a slight variation in the thickness of the body, for example, at a peripheral area of the center parts 56, 58 of the second portion. For example, as shown in FIG. 2A, which is an enlarged cross-sectional view taken along line 2A-2A in FIG. 1, the center parts 56, 58 are shown as including an indentation 62 at their periphery. The indentation may contribute to an improved handling of the gaming chip by a user, counter or sorter, or may facilitate placement of a decorative sticker on the surface of the gaming chip, if desired, or merely provide a desirable aesthetic feature.

The gaming chip as described herein may be manufactured according to any suitable method. However, in a specific embodiment, the gaming chip according to the present invention is formed by injection molding the composite material. If the gaming chip is formed from a homogeneous composite material of a single color, the gaming chip may be injection molded in a single step according to conventional injection molding techniques. In a specific embodiment of this method, a gaming chip as shown in FIGS. 1 and 2 is formed from two portions of the composite material, wherein the portions are of different colors. For example, as shown in FIG. 5, a first portion of a first colored composite material is formed by injection molding in a mold configured to provide the first portion with the desired indentations and, optionally, apertures. In the embodiment shown in FIG. 5, for example, the mold 70 includes an upper mold half 71 a and a lower mold half 71 b which cooperate to form a recess in the shape of the first portion 20. The mold 70 further includes pins 72 which form the apertures 40 of the first portion as shown in FIG. 4. In a second step of the injection molding process, the thus formed first portion 20 is transferred to a second mold which is configured to allow injection molding of the second portions in the surface indentations of the first portion 20. The mold will also allow injection molding of the composite material forming the second portion in the apertures 40 contained in the first portion 20. The apertures 40 facilitate injection molding of the second portions as the composite material may be injection molded through the apertures to distribute material to indentations on both faces 22A and 22B of the first portion 20.

Accordingly, the aperture in the first portion facilitates manufacture of the present gaming chips in two or more colors in mass quantities using injection molding techniques. One skilled in the art will appreciate that other plastic molding techniques and/or other manufacturing techniques may be used in preparing gaming chips according to the invention and the resulting gaming chips are equally within the scope of the present invention.

The size of the gaming chip, including the thickness and diameter, may be varied in order to increase or decrease the weight and substantive feel of the chip. In one embodiment, the chip is configured to have a weight of from about 5 to about 15 grams, more specifically from about 5 to about 10 grams, more particularly of about 8.5 grams.

The examples and specific and preferred embodiments set forth herein are exemplary in nature only and are not intended to be limiting of the gaming chips and methods defined by the following claims. Additional examples and embodiments of the invention will be apparent to those of ordinary skill in the art and are encompassed by the following claims. 

1. A gaming chip, formed of a composite material comprising a polymer and from about 5 to about 50 percent by weight of inorganic filler.
 2. The gaming chip of claim 1, wherein the polymer comprises polyolefin.
 3. The gaming chip of claim 1, wherein the polymer comprises polypropylene.
 4. The gaming chip of claim 1, wherein the filler comprises metal oxide, metal hydroxide, metal carbonate, or a mixture of two or more thereof.
 5. The gaming chip of claim 1, wherein the filler comprises clay, calcium carbonate, or a mixture thereof.
 6. The gaming chip of claim 1, wherein the composite material comprises from about 50 to about 95 percent by weight polypropylene and from about 5 to about 25 percent by weight calcium carbonate filler.
 7. The gaming chip of claim 1, comprising at least one first portion in which the composite material comprises a first colored pigment, and at least one second portion in which the composite material comprises a second colored pigment different from the first colored pigment.
 8. The gaming chip of claim 7, wherein the first portion extends substantially around a perimeter of the chip and substantially across a body of the chip within the perimeter of the chip.
 9. The gaming chip of claim 8, wherein the first portion is provided with at least one surface indentation in which the second portion is located.
 10. The gaming chip of claim 8, wherein each body surface of the first portion is provided with at least one indentation and a second portion is located in each indentation.
 11. The gaming chip of claim 10, wherein the perimeter of the first portion includes indentations and a second portion is located in each indentation.
 12. The gaming chip of claim 10, wherein the first portion is provided with apertures extending between the body surfaces.
 13. The gaming chip of claim 1, wherein the gaming chip is injection molded.
 14. A method of manufacturing a gaming chip, comprising injection molding a composite material in the form of a gaming chip, the composite material comprising a polymer and from about 5 to about 50 percent by weight of inorganic filler.
 15. The method of claim 14, comprising injection molding a first portion including a chip perimeter and a chip body extending within the chip perimeter, the first portion having at least one surface indentation, and injection molding a second portion to at least partially fill the indentation.
 16. The method of claim 15, wherein the first portion comprises a first colored pigment, and the second portion comprises a second colored pigment different from the first colored pigment.
 17. The method of claim 15, wherein each body surface of the first portion is provided with at least one indentation and a second portion is injection molded into each indentation.
 18. The gaming chip of claim 17, wherein the first portion is provided with apertures extending between the body surfaces and at least one of the second portions is formed by injecting composite material from one body surface to the other body surface through the apertures.
 19. The method of claim 15, wherein the perimeter of the first portion includes indentations in which second portions are injection molded.
 20. The method of claim 15, wherein the first portion and the second portions are injection molded to be substantially coplanar on faces of the gaming chip. 